Variable-speed actuator

ABSTRACT

A valve actuator including an electric motor is disclosed that includes a solid-state motor controller capable of operating a motor at variable speeds and a gear set that provides inherent braking. The speed and torque of the valve actuator may be selected. The speed and torque experienced by a valve may be varied over the length of a valve stroke. The valve actuator may include logic sufficient to act as a process controller.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.13/054,704, filed Apr. 6, 2011, now U.S. Pat. No. 9,188,237 issued Nov.17, 2015, which is a national phase entry under 35 U.S.C. §371 ofInternational Patent Application PCT/US2008/070545, filed Jul. 18, 2008,published in English as International Patent Publication WO 2010/008398A1 on Jan. 21, 2010, the disclosure of each of which is herebyincorporated herein in its entirety by this reference.

TECHNICAL FIELD

The invention relates generally to valve actuators including electricmotors and, more particularly, to the control of such valve actuators.

BACKGROUND

Valve actuators find wide application in a number of industries, suchas, power generation of all types, petroleum and petrochemicals,textiles, paper, and food processing. The operating speed and torqueprovided by a valve actuator are important parameters. Generally, afixed speed motor is coupled to a gear set to provide just the rightcombination of speed and torque to a valve. The exact motor and gear sethave to be coupled by a manufacturer. If a manufacturer wants to have aquick turnaround time to customer orders, the manufacturer must stock awide variety of motors and gear sets. Additionally, a specializedworkforce must be employed that is knowledgeable in the assembly ofsometimes hundreds of different variations on a single generic valveactuator design.

Furthermore, even if multiple customers want a valve actuator withexactly the same speed and torque characteristics, often customers willhave different power supplies available. One customer may want to use480 VAC three-phase at 60 Hz; another customer may want to use 110 VACsingle-phase at 50 Hz; and yet another customer may only have 24 VDCavailable. Previously known systems do not provide a valve actuator thatis supplied off-the-shelf to meet the needs of customers with differentpower supplies available.

Currently, if a user wants to change the torque and speedcharacteristics of a valve actuator, the actuator has to be pulled fromservice, disassembled, and then reassembled with a different gear setsand/or motor. What is needed is a way to reduce the number of motors andgear sets that must be stocked to meet customer needs. There is afurther need to reduce the number of models that employees must betrained to build. Additionally, there is a need to permit adjustment ofthe speed and torque delivered by an actuator without requiringdisassembly.

Additionally, fixed speed valve actuators have limited utility asprocess controllers because the valve is always operated at a fixedspeed. What is needed is a way to allow a valve actuator to operate as aprocess controller.

One attempt to solve these problems was through the use of a rectifierand chopper to control the current sent a DC motor. This allowed forhigh or low voltage AC current that was either single- or three-phase tobe used and allowed the speed and torque of the motor to be controlled.A variation on this attempt was to rectify AC, then use an inverter tocontrol an AC motor. However, these attempts required the use of torquelimit switches. An operator could mechanically adjust the speed andtorque delivered by a valve actuator, but at most, an operator couldonly set a maximum torque or speed that should not be exceeded by thevalve actuator. An operator could not set a speed or torque profile thatwould vary over the length of a valve stroke without limit switches. Agear set was included with the valve actuator and was located within thehousing of the valve actuator.

The previous attempts require a user to adjust speed and torquepotentiometer and do not permit an operator to set a speed or torqueprofile that would vary over the length of a valve stroke. Theseattempts do not provide a way to set the speed and torque of a valveactuator without bulky mechanical switches and torque limit switches,nor do they provide a mechanism where the valve actuator could operateas a process controller.

Other attempts to solve the above problems have used switched reluctancemotors and DC motors to provide variable speeds. However, in thosecases, the valve actuator requires a separate braking mechanism to keepthe motor from spinning in the event of a power loss. What is needed isa valve actuator capable of variable speeds that simply and inherentlyhas braking capabilities.

DISCLOSURE OF THE INVENTION

One embodiment of the invention is a valve actuator comprising avariable-speed motor, a solid-state motor controller operably connectedto the variable-speed motor and configurable to operate thevariable-speed motor, and a worm/worm-gear set operably connected to thevariable-speed motor.

Another embodiment of the invention is a valve actuator comprising auniversal field-connection block, a power converter operable to receivea power supply, a variable-speed motor, a solid-state motor controlleroperably connected to the power converter and the motor controllerconfigurable to operate the variable-speed motor, and a braking deviceoperably connected to the variable-speed motor, the braking devicecomprised of a gear set.

Yet another embodiment of the invention includes a valve actuatorcomprising a housing, a motor controller, a variable-speed motor with anoutput shaft, wherein the variable-speed motor is configured for controlby the motor controller, and the motor controller and the variable-speedmotor integrated within the housing and a gear train outside of thehousing and operatively coupled to the output shaft.

A particular embodiment of the invention includes a method of operatinga valve actuator, the method comprising providing a valve actuatorcomprising a solid-state motor controller operably connected to avariable-speed motor, wherein a gear set is operably connected to thevariable-speed motor, setting the speed on the solid-state motorcontroller at which the variable-speed motor will be driven by thesolid-state motor controller when the valve actuator is operated, andlocking the variable-speed motor with the gear set against back-drivingloads in the event of a power failure.

Another embodiment of the invention includes a method of actuating anelectrically driven valve actuator, the method comprising receiving acommand signal at a solid-state valve actuator controller operablyconnected to the electrically driven valve actuator including a gearset, wherein the electrically driven valve actuator is capable ofvariable speeds, receiving a feedback signal at the solid-state valveactuator controller, determining if there is a difference between thecommand signal and the feedback signal, and minimizing any differencebetween the command signal and the feedback signal by actuating theelectrically driven valve actuator.

Another embodiment of the invention is a system for actuating a valve,the system comprising: a valve actuator, wherein the valve actuatorcomprises a motor, wherein the motor comprises an output shaft, asolid-state motor controller operably connected to the motor and capableof operating the motor at variable speeds and torques, and aworm/worm-gear set coupled to the output shaft of the motor.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming that which is regarded as the present invention,this invention can be more readily understood and appreciated by one ofordinary skill in the art from the following description of theinvention when read in conjunction with the accompanying drawings inwhich:

FIG. 1 is a schematic view of an embodiment of a valve actuator capableof variable speeds, including a motor controller and motor capable ofvariable speeds;

FIG. 2 illustrates the addition of a power converter and gear set to theembodiment shown in FIG. 1;

FIG. 3 illustrates merging the power converter and the motor controlleraccording to an embodiment of the invention;

FIG. 4 illustrates an embodiment of the invention without a powerconverter;

FIG. 5 illustrates an embodiment that includes a field-connectionterminal as part of the valve actuator according to an embodiment of theinvention;

FIG. 6 illustrates an embodiment of a power converter without a gearset;

FIG. 7 illustrates an embodiment of a valve actuator where a motorcontroller and a variable-speed motor are within a separate housing anda gear set located external to the housing;

FIG. 8 illustrates the inclusion of a valve actuator controlleraccording to an embodiment of the inventive valve actuator;

FIG. 9 illustrates an embodiment of the invention where a powerconverter is integrated as part of a motor controller in communicationwith a valve actuator controller;

FIG. 10 illustrates an embodiment of the invention where a motorcontroller is integrated as part of a valve actuator controller thatreceives input from a power converter;

FIG. 11 illustrates the combination of a power converter, motorcontroller, and valve actuator controller within a single deviceaccording to an embodiment of the invention;

FIG. 12 illustrates examples of different feedback signals that may bereceived by a motor controller; and

FIG. 13 illustrates an embodiment of a valve actuator operating as aprocess controller.

DETAILED DESCRIPTION OF THE INVENTION

A valve actuator including an electric motor is disclosed that includesa solid-state motor controller capable of operating a motor at variablespeeds and a gear set that prevents load forces from back-driving anoutput shaft. The speed and torque of the valve actuator may beselected. The invention can obviate the need to install torque limitswitches or other torque-dedicated torque-sensing means and separatebraking mechanisms in a valve actuator.

For ease of discussion, the same numerals can represent similar elementsin the figures. Referring now to FIG. 1, a particular embodiment of avalve actuator 100 comprises motor controller 20 and variable-speedmotor 10. Motor controller 20 receives electrical input from powersupply 90. Motor controller 20 controls the output of electrical energyto variable-speed motor 10. Variable-speed motor 10 may be coupled tovalve 80. Alternatively, variable-speed motor 10 may be coupled to anactuator gear box (rotational or linear output), which, in turn, may becoupled to valve 80 or other driven load.

Variable-speed motor 10 may be any suitable motor known in the art.Numerous variable-speed motors are contemplated by the invention.Virtually any AC motor, with the proper controller and converter mayfunction at variable speeds. Variable-speed motor 10 includessingle-phase and poly-phase induction motors. Included within thepoly-phase induction motors are the four general groups of Designs A &B, C, D, and F and the accompanying subgroups. Variable-speed motor 10may be other AC motors, such as, wound-rotor motors, multi-speed motors,constant and variable-torque motors, and universal motors. Synchronousmotors including non-excited synchronous motors, both hysteresis andreluctance designs, and DC-excited synchronous motors may be used.Variable-speed motor 10 may also be a servomotor, brushless servomotor,and linear motor.

Variable-speed motor 10 may also be a DC motor. Suitable DC motorsinclude, for example, shunt-wound, series-wound, compound-wound, andbrushless DC motors. Variable-speed motor 10 may also be a brush orbrushless DC linear motor or a coreless motor. Variable-speed motor 10may have any number of poles, such as when a ring motor or pancake motoris used. Variable-speed motor 10 may be a limited-angle torque motor ora brushless DC motor wired as a limited-angle torque motor.Variable-speed motor 10 can include permanent magnet stepper motors(such as disk-type motors), magnet-less brushless stepper motors (suchas variable reluctance motors), and switched reluctance brushless DCmotors (also known as hybrid permanent-magnet motors). Variable-speedmotor 10 can include stepper motors, such as two-, three-, four-, orfive-phase motors, and DC servomotors.

The foregoing list of motors is not meant to be limiting, but rather toprovide examples of the wide variety of motors that may be used asvariable-speed motor 10. Any motor that can be driven at variable speedsby any method of control may be used as variable-speed motor 10.Additionally, although servomotors have been delineated as a specifictype of motor, it should be understood that motor position feedbackcould be integrated with any of the above motors.

Motor controller 20 may be any controller capable of controlling thespeed and torque of variable-speed motor 10. In one embodiment, motorcontroller 20 can be a solid-state controller. The term “controller” isused herein to refer to both controllers and drives. Motor controller 20will vary depending upon the type of motor used. DC motors with brushesare comprised of mainly a wound stator called the “field” and a woundrotor called the “armature.” “Windings” or “wound” as the term is usedherein, refers not only to wire wrappings, but also to metal layers andto the frame for the windings (which typically comprise ferrous metallaminations). For example, for a series-wound DC motor, the armature andthe field are connected in series. The motor speed is approximatelydirectly proportional to the current fed to the motor. Therefore,controlling the voltage that is fed to the motor will control the speedof the motor. Controlling the current will control the motor torque.Motor controller 20 may include a variable resistor, such as apotentiometer or rheostat. For example, triacs and silicon-controlledrectifiers (SCRs) may also be used. Any suitable technique compatiblewith the variable-speed motor 10 may be used.

Shunt-wound DC motors have separate field and armature power supplies.Therefore, a different type of control is required. When the field has afixed supply and the armature supply is varied, this is referred to as“armature-voltage control.” Armature-voltage control provides forconstant torque over the speed range. When the field is varied and thearmature supply is fixed, this is referred to as “shunt-field control.”Shunt-field control provides for constant horsepower over a speed range.Compound-wound DC motors use both series and shunt-field windings. Motorcontroller 20 may provide armature-voltage control, shunt-field control,or compound-wound motor control.

Brushless DC motors do not have a wound armature, but instead use apermanent magnet as the rotor. Instead of brushes, the current in thefield windings (laminated metal layers) is switched back and forth asnecessary to create the required alternating magnetic fields to spin thepermanent magnet rotor. PWM is commonly used to control the switchingspeed; however, motor controller 20 may employ any suitable method tocontrol speed and/or torque.

AC induction motors have a wound stator rotor and may have a rotor withwound windings or conductive “bars” (squirrel cage), but power is onlyfed to the stator. The speed of AC motors is most often controlled byvarying the power supply frequency and voltage. In a particularembodiment of the invention, motor controller 20 may be a variablefrequency drive (VFD). A VFD essentially converts AC to DC and theninverts the DC current back into AC. The inverter controls the voltageand frequency of the output AC wave. The output frequency determines thespeed of the AC motor. The output voltage determines the motor torque.Suitable devices that can be used to accomplish AC-to-DC conversioninclude, for example: diodes, rectifiers, thyristors, and SCRs.Semiconductors, such as insulated (also referred to as isolated) gatebipolar transistors (IGBTs), may be used to invert the DC current to ACcurrent. Alternatively, bipolar transistors, FETs, MOSFETs, andtransistor-transformers may be used. Synchronous motors are controlledin a similar manner as induction motors. Motor controller 20 may be anysuitable controller capable of controlling the speed and/or torque of anAC motor known in the art.

FIG. 2 illustrates an embodiment of the invention where the valveactuator 100 further includes a power converter 30 and gear set 40.Power converter 30 receives electrical input from power supply 90 andoutputs an appropriate electrical supply to motor controller 20. Gearset 40 is coupled to the output shaft of variable-speed motor 10. Gearset 40 is, in turn, coupled to valve 80.

In another embodiment shown in FIG. 3, power converter 30 may beintegrated within the same housing as motor controller 20. Some or allof the functions of power converter 30 may also be accomplished by motorcontroller 20. For example, when a VFD is used as the motor controller20, the VFD can also perform the function of converting single-phase ACto three-phase AC. Therefore, a separate phase converter is notnecessary. However, it may be desirable to have a separate phaseconverter built into the universal power converter 30 rather thanutilizing a VFD for this purpose. VFDs can also perform AC-to-DCconversion and inversion back to AC. Therefore, when motor controller 20includes a VFD, those aspects of power conversion could be performed bythe motor controller 20.

Additionally, as shown in the embodiment of FIG. 4, there may besituations where power converter 30 is not required. Power converter 30may be a transformer (e.g., a variable transformer) capable of changingthe power supply 90 from one voltage to another voltage. Power converter30 may also be an AC-to-DC converter, DC-to-DC converter, DC-to-ACinverter, or a phase converter. Power converter 30 may also be designedto be a universal power converter. Thus, power converter would be ableto take any commonly used voltage and current type and convert it into aform usable by the motor controller 20. In an alternative embodiment,the power converter can create low voltage ac and/or dc power that canpower the on-board position or process controller and also may sourcepower to drive external devices (e.g., switches, indicators, and statussignals). Power supply 90 may be any power supply available. A fewexamples of power supply 90 include: 208 to 690 VAC three-phase, 50 or60 Hz; 120 or 230 VAC, single-phase; 12 VDC; 24 VDC; and 48 VDC.Embodiments of the present invention may be able to accept any voltagefrom 24 VDC up to 690 VAC.

Power converter 30 may be a single device or multiple devices. Forexample, power converter 30 may include the previously mentioned DCconverter, an AC step-down or step-up transformer, or a phase converter.

Referring to the embodiment of FIG. 5, field-connection block 60 mayalso be included in the valve actuator 100. Field-connection block 60may be designed in any manner necessary to connect power supply 90 toeither power converter 30 or motor controller 20. Field-connection block60 may also be integrated into a single device with power converter 30and/or motor controller 20. Field-connection block 60 could be designedas a universal connection block for use with a universal power converter30. In that particular embodiment, the field-connection block 60 couldbe designed with the appropriate posts, lugs, cam locks, pin and sleeveconnectors, or other connection devices to handle any voltage oramperage delivered by power supply 90. The field-connection block 60could also have a single connection mechanism or multiple connectionmechanisms. For example, field-connection block 60 may have a single setof posts upon which lugs may be secured for both AC and DC wires.Alternatively, field-connection block 60 may have a set of posts and/orlugs for DC wires, and a set of posts and/or lugs for AC wires.Field-connection block 60 may also have multiple sets of AC and DCconnection mechanisms.

Field-connection block 60 may be designed to protect against an operatorerroneously wiring the field-connection block 60 for one type of power,but actually supplying a different type of power. For example, if anoperator desires to utilize 480 VAC three-phase, but accidentallyconnects two of the 480 VAC conductors to a set of DC lugs, thenproblems may result. Field-connection block 60 may be designed toautomatically sense the type of current and voltage being supplied andtake appropriate precautions, or a mechanism may be provided allowing auser to identify what current and voltage will be supplied. Automaticsensing can be accomplished with sensors as are known in the art. Acontroller within field-connection block 60 can then engage theappropriate switchgear to electrically connect the operator's powersupply to the appropriate portions of power converter 30. A powerconditioner module may accept any of a wide range of possible inputvoltages and either permit operation (if within safety limits) orprevent motor operation. Circuit protection can be added to avoid tryingto alter the switchgear while current is flowing through the contacts.

Furthermore, when variable-speed motor 10 is an AC motor, and powersupply 90 is a DC power supply, then it may be desirable to directlyfeed the DC power to motor controller 20, which, in turn, will invertthe DC power to AC power as part of controlling variable-speed motor 10.

Field-connection block 60 or any other portion of valve actuator 100 mayinclude any necessary current and voltage protection, such as in theform of circuit breakers and surge protectors.

All of the structures and functions described with respect tofield-connection block 60 may also be integrated within a single housingwith power converter 30, motor controller 20, and/or valve actuatorcontroller 50. That single housing could then be incorporated as part ofthe valve actuator 100. Additionally, field-connection block 60 andpower converter 30 may be fully integrated.

By using a universal power converter 30, a valve actuator manufacturercould make a single valve actuator 100 in a given size range that wouldbe compatible (and off-the-shelf) with any power supply 90 a customermight have. Additionally, by utilizing the variable-speed motor 10, thevalve actuator 100 can be compatible with a wide range of valves 80. Thesolid-state motor controller 20 allows configuration of optimum speedand torque for a given valve 80. The speed and torque could be set by anoperator, manufacturer, agent, or distributor. Therefore, a narrow rangeof valve actuators 100 are able to meet the needs of a wide range ofvalve applications. The narrow range of valve actuators 100 could beproduced in a high enough volume to achieve economies of scalepreviously not possible with other valve actuators.

Valve actuator 100 optionally includes gear set 40. Gear set 40 may beincluded as part of valve actuator 100 or as a separate piece that maybe coupled to valve actuator 100. In one embodiment, the gear set 40 maybe a worm/worm-gear set where the worm shaft is directly coupled to theoutput shaft of variable-speed motor 10 and integrated as part of valveactuator 100. The worm/worm-gear set inherently provides braking orlocking for the valve actuator 100 to keep the valve from changingposition when the motor is not energized. However, gear set 40 may beother gears such as planetary gear sets. FIG. 6 illustrates anembodiment where the gear set 40 is not present. In this embodiment, theoutput shaft of the variable-speed motor 10 can be directly coupled tothe valve 80.

It is understood that in particular embodiments, a hollow shaft, highpole count, high torque, low speed “pancake” motor could be used toaccept the valve stem and directly drive the valve—without a gearbox.For a direct drive, hollow shaft actuator, we would still need to “lock”the actuator in position when stopped. It could be actively held in thatposition by the controller via a zero speed command to the motorcontroller. Alternatively, the hollow shaft design could use athree-position motor/handwheel clutching system and solenoid-drivenbrake. The first position includes motoring with a solenoid brakereleased or stopped with the solenoid-driven brake engaged. The secondposition includes the motor being disengaged and the brake engaged(i.e., overrides the solenoid). The third position includes the motorbeing disengaged, the brake being disengaged (overrides solenoid), andthe handwheel being engaged. To operate the handwheel, the lever ismoved to position three, the handwheel is turned to a desired valveposition, and the lever is moved to position one or two to hold thevalve position.

FIG. 7 illustrates an embodiment where the gear set 40 is present in thevalve actuator 100, but the variable-speed motor 10 and the motorcontroller 20 are contained within a separate housing 70. A powerconverter 30 may also be present within the housing 70. In oneembodiment, housing 70 is a motor housing. For example, the motorcontroller 20 and power converter 30 may be placed within the motorhousing. Alternatively, motor controller 20 and power converter 30 maybe placed on housing 70. In such an embodiment, the motor controller 20and power converter 30 may be wired to the variable-speed motor 10through a hole in the housing 70. The motor controller 20 and powerconverter 30 could be suitably covered so that housing 70 has anydesired NEMA rating, such as NEMA 4. Additionally, in the embodiments ofFIG. 7, the power converter 30 may not be present or may be integratedwith the motor controller 20 into a single device. Valve actuatorcontroller 50 may also be located within housing 70. Motor controller 20may also be integrated within valve actuator controller 50.

Valve 80 may be a multi-turn or quarter-turn valve. Valve 80 may be aglobe, gate, sluice, butterfly, plug, ball, or multi-port valve. Valve80 includes any valve or other actuator-driven loads that may beoperated by variable-speed motor 10 with or without gear set 40.

Referring to FIG. 8, valve actuator 100 may also include valve actuatorcontroller 50. Valve actuator controller 50 in a particular embodimentis located within actuator housing 70 of valve actuator 100. However,valve actuator controller 50 may alternatively be external to actuatorhousing 70. For example, valve actuator controller 50 may be mounted ona support structure near the valve actuator 100 with electrical leadsconnecting the valve actuator controller 50 to the valve actuator 100.

In one embodiment, as shown in FIG. 8, valve actuator controller 50controls motor controller 20. Motor controller 20 may be separate frompower converter 30, as shown in FIG. 8, or power converter 30 may beintegrated into the same device as motor controller 20, as shown in FIG.9. FIG. 8 illustrates valve actuator controller 50 as separate frommotor controller 20. Alternatively, valve actuator controller 50 maydirectly receive power from power supply 90 and valve actuatorcontroller 50 may send output signals and status indicators to powersupply 90. However, as shown in FIG. 10, motor controller 20 may beintegrated into a single device with valve actuator controller 50. FIG.11 illustrates that power converter 30 may also be integrated into asingle device with valve actuator controller 50 and motor controller 20.

It is understood that although the figures show integrating the motorcontroller 20 into valve actuator controller 50, valve actuatorcontroller 50 may also be viewed as being integrated into motorcontroller 20. Similarly, the functions performed by motor controller 20and/or valve actuator controller 50 may also be performed by powerconverter 30.

The valve actuator controller 50 is capable of both receiving andoutputting signals. Valve actuator controller 50 may receive processcommand signals, process feedback signals, valve position commandsignals, valve position feedback signals, and motor position signals.Either valve actuator controller 50 or motor controller 20 may receiveany number of feedback signals. For example, as illustrated in FIG. 12,variable-speed motor 10 may generate a feedback signal 15 such as arotor (or armature) position signal(s), rotor speed signal, motorcurrent signal, or motor torque signal. Feedback signal 15 could be usedto derive the valve actuator 100 output torque, output speed, andposition. Similarly, feedback signal 15 may be used to calculate valve80 torque, speed, and position. Gear set 40 may be configured togenerate feedback signal 16. Feedback signal 16 may indicate valveactuator 100 output torque, speed, and/or position. Feedback signal 16may also include data on any portion of the gear train, such as thespeed and/or torque of a worm shaft or worm gear. Additionally, valve 80may be configured to generate feedback signal 17. Feedback signal 17 maybe used to directly indicate valve 80 torque, speed, and position. FIG.12 illustrates motor controller 20 receiving feedback signals 15, 16,and 17. However, valve actuator controller 50 may also receive thesignals.

Examples of signals that may be sent by valve actuator controller 50include queries to sensors, operators, motor controller 20,variable-speed motor 10, and other systems outside the valve actuator100.

Valve actuator controller 50 may operate as a position controller or aprocess controller. In the position controller embodiment, valveactuator controller 50 can be configured to receive a position commandsignal. The position command signal can indicate a desired position ofthe valve. The command signal may be generated by any standard means,such as by a process controller, an operator, switches, potentiometers,process function blocks, signal generators, or position controller. Thevalve actuator controller 50 can then use the motor controller's 20knowledge of the rotor position of variable-speed motor 10, via feedbacksignal 15, to determine the position of valve 80. Feedback signal 15 canessentially serve as the source of a position feedback signal. Valveactuator controller 50 can then determine if there was an error (adifference) between the position command signal and the positionfeedback signal. If an error is detected, valve actuator controller 50can then adjust valve actuator 100 to minimize the error. Performancetuning (e.g., response time, allowable overshoot, settling time, and/orallowable error) may be configured by the user or preset to defaultvalues by the manufacturer.

In the process controller embodiment, valve actuator controller 50 wouldbe configured to receive a process command signal and a process feedbacksignal. The process command signal indicates a desired process variableset-point. The process feedback signal indicates the actual condition ofthe process variable. Valve actuator controller 50 would then determineif there was an error between the two signals and adjust the valve toreduce the error to within a configured acceptance band. Valve actuatorcontroller 50 may incorporate any type of control response, such as,proportional control, proportional plus integral control, proportionalplus integral plus derivative control, or proportional plus derivativecontrol.

Valve actuator 100 may be configured to operate valve 80 at either afixed speed or at a variable speed. In the fixed speed embodiment, theinventive valve actuator 100 may provide improved manufacturingeconomies of scale. Additionally, valve actuator 100 may be configuredto operate at variable speeds.

Valve actuator 100 may be configured by an operator to operate atvariable speeds. An operator can have nearly infinite control over thespeed at which valve 80 is operated. An operator can choose a set speedfor the valve actuator 100 to operate at or can enter a speed profile. Aspeed profile allows an operator to designate different valve speeds fordifferent portions of the valve 80 stroke. The operator can also set theallowable torque that may be delivered at different speeds and atdifferent locations along the stroke of valve 80. Therefore, the torqueand speed of valve 80 can be limited before opening, when first opening,before closing, or when first closing valve 80. In a particularembodiment, valve actuator controller 50 and/or motor controller 20 aresolid-state controllers, eliminating the need for torque limit switchesto identify when the speed or torque should be changed. Instead, motorcontroller's 20 knowledge of motor position and torque via feedbacksignal 15 could be used to determine when to limit or vary the torqueand/or speed of valve 80. For example, torque may be deduced fromknowledge of motor current, voltage, temperature, back EMF, leakageflux, or any combination thereof. Therefore, when valve actuatorcontroller 50 is a solid-state controller, the operator can change theposition along a valve stroke where the speed reduces or increaseswithout having to adjust mechanical switches.

The ability of an operator to vary the fixed speed or speed profile ofvalve 80 can provide greater flexibility with determining overall systemgain. For example, a higher valve speed may equate with a higher systemgain and, conversely, a lower valve speed may equate with a lower systemgain. Furthermore, because of the relationship between valve speed andsystem gain, the variable-speed ability of valve actuator 100 provides atool to an operator to fine tune a control system. This may beparticularly advantageous in sensitive control systems where it isdifficult to find tuning constants that allow a system to calm down.

Additionally, once tuning constants are selected, an operator can varythe speed of valve 80 rather than alter the tuning constants. This maybe particularly advantageous in a process where an operator has alimited set of tuning constants that avoid problems associated with PIDcontrollers, such as integral wind-up and other problems known in theart. In such a scenario, adjusting valve speed may be more beneficialthan changing the controller tuning constants.

For example, many operators try to avoid shutting down a process toperform maintenance on a valve. Instead, an operator will try to keep avalve sufficiently operational until a given time of year when theentire process will be shut down and any needed repairs are performed atone time. Therefore, when a valve starts sticking, some operators willadjust the tuning constants of a controller to try to compensate for thesticking valve. Essentially, an operator may change the controllertuning constants to try to command the valve to change position sooneror to a greater degree in order to approximate an actual result that issimilar to the pre-sticking valve process condition. Alternatively, theclosed loop position controller of the present invention can adjust themotor voltage as necessary, all the way up to full voltage (max tq) inan attempt to achieve the command speed. By adjusting a timer or the Kiconstant in the controller's timing parameters, the operator may adjustthe behavior of an actuator as a valve grows more sticky.

However, for complex or sensitive systems, there may be a limited set oftuning constants that actually provide for a stable process. Byadjusting the valve actuator controller 50 to vary the speed at valve80, rather than just varying a fixed speed, a valve speed profile can beadjusted or created to accommodate whatever problem the valve is having.If a valve is sticking only upon opening, then greater torque could besupplied when first opening the valve. If a valve is sticking in themiddle of the valve stroke, then the speed or torque could be increasedover the range where the valve is sticking.

Valve actuator 100 may be designed with appropriate logic in valveactuator controller 50 to determine the speed at which to actuate valve80. Such logic can be integrated into the valve actuator controller 50when valve actuator controller 50 is functioning as a processcontroller. In this embodiment, valve actuator controller 50 candetermine at which speed variable-speed motor 10 will operate to turngear set 40 and, in turn, actuate valve 80. For example, valve actuatorcontroller 50 may be designed so that valve 80 is actuated at a highspeed when the difference between a process variable set point andprocess variable feedback is large. Likewise, when the error (thedifference) between process signals is small, then valve 80 is actuatedat a low speed. Valve actuator controller 50 may be set with a limitedset of speeds pre-selected to correspond to a given magnitude of error.Alternatively, valve actuator controller 50 may have essentiallyinfinite speeds at which valve 80 may be actuated depending upon thecorresponding error.

Valve actuator controller 50 may also be designed so that a firstresponse to a process variable set-point change results in valve 80being actuated at a high speed, and subsequent changes to the positionof valve 80 occur at lower and lower speeds. Such an approach may beuseful in avoiding integral wind-up. Valve actuator controller 50 may bedesigned to respond in numerous ways, as will be apparent to one ofordinary skill in the art. Programming controllers and controllerhardware are known in the art. Therefore, the exact software, hardware,and/or firmware used in valve actuator controller 50 is not discussedherein.

Referring to FIG. 13, one example of using valve actuator controller 50as a temperature process controller is described. Reactor vessel 200 hasa heating jacket 210 around its sides. The inputs and outputs of reactorvessel 200 have not been shown. Pipe 220 supplies hot water to heatingjacket 210. The heat from the hot water in heating jacket 210 istransferred to reactor vessel 200. The greater the flow rate of freshhot water into heating jacket 210, the higher the temperature of reactorvessel 200. The flow rate of hot water is controlled by valve 80. Theinlet of valve 80 is connected to pipe 260. Hot water that hascirculated through heating jacket 210 exits via pipe 270. Valve 80 isturned by valve actuator 100. Signal 240 is the process command signalsent to valve actuator controller 50 indicating the temperatureset-point for reactor vessel 200. The source of signal is not indicatedin FIG. 13. Signals 240 and 250 may be in the form of a 0-20 or 5-20 mAsignal, 0-10 or 0-50 mV signal, 0-5, 1-5, or 0-10 Vdc signal, or adigital message on a digital communication bus (Modbus, FoundationFieldbus, Profibus, ASi, DeviceNet, Internet, Ethernet, etc.) or anyother controller signal form. Signal 250 is the process feedback signalsent to valve actuator controller 50 from temperature sensor 230.

For simplicity, in this example, the position of valve 80 is assumed tobe calibrated to different flow rates of hot water. In practice, atleast one hot water flow sensor, as well as other sensors, may also feedsignals to valve actuator controller 50. Additionally, any number oftemperature sensors 230 may be used.

When a minor change in temperature is sensed by temperature sensor 230,valve actuator controller 50 may, in response, change the position ofvalve 80 a corresponding minor amount and at a relatively slow speed.Alternatively, should a large temperature drop be sensed, then valveactuator controller 50 may open valve 80 a greater amount and at arelatively higher rate of speed. Valve actuator controller 50 may have agiven set of speeds, such as very low, low, medium, high, and very high,that, depending upon the degree of difference between signal 240 andsignal 250, determines which speed is used to actuate valve 80. Valveactuator controller 50 may also have an essentially infinite number ofspeeds at which the valve 80 may be actuated. Valve actuator controller50 may be configured to also sense not only the difference betweensignals 240 and 250, but changes to signal 240 itself. For example,should the temperature set-point be dramatically increased by anoperator, the valve actuator controller 50 may open valve 80 slowly togradually increase the temperature of reactor vessel 200. However,should a change in signal 250 be the source of the error between signals250 and 240, then the valve actuator controller 50 can cause valve 80 tochange position rapidly.

Valve actuator controller 50 may be primarily software, hardware,firmware, or combinations thereof. Valve actuator controller 50 may bedesigned to interface with a PC, or to interface with other controlhardware and software. Motor controller 20 and valve actuator controller50 may receive power from either power supply 90 or a separate powersupply, as is known in the art.

The present invention also includes the following particular embodimentsand concepts:

A valve actuator comprising: a variable-speed motor; a solid-state motorcontroller operably connected to the variable-speed motor andconfigurable to operate the variable-speed motor; and a gear setoperably connected to the variable-speed motor.

The valve actuator can include a variable-speed motor selected from thegroup consisting of an AC synchronous reluctance motor with motorposition feedback, an AC synchronous reluctance motor without motorposition feedback, a DC brushless motor with motor position feedback,and a DC brushless motor with motor position feedback. Alternatively,the variable-speed motor can be an AC motor selected from the groupconsisting of: single-phase induction motors, poly-phase inductionmotors, wound-rotor motors, multi-speed motors, constant torque motors,variable torque motors, universal motors, synchronous hysteresis motors,DC-excited synchronous motors, servomotors, brushless servomotors, andlinear motors. In another embodiment, the variable-speed motor can alsobe a DC motor selected from the group consisting of: shunt-wound,series-wound, compound-wound, brushless DC motors, linear motors,brushless linear motors, coreless motors, ring motors, pancake motors,limited-angle torque motors, permanent magnet stepper motors, variablereluctance motors, switched reluctance motors, and servomotors.

In yet another embodiment, the valve actuator can further include apower converter. The power converter may be operable to perform one ormore of the following functions comprising: AC-to-AC transforming,DC-to-DC converting, AC-to-DC converting; DC-to-AC inverting; and phaseconverting. The power converter and the solid-state motor controller mayoptionally be integrated into a single device. The solid-state motorcontroller may be operable to vary the speed and torque of thevariable-speed motor. Alternatively, the solid state motor controllermay have a set of preselected speeds and torques at which the variablespeed motor is operated. The solid-state motor controller may also havea preselected torque that is limited by the user. The solid state motorcontroller may optionally have a set of preselected speed and torqueprofiles at which the variable speed motor is operated.

In yet another embodiment, the valve actuator may further include avalve actuator controller operable to control the motor controller.

In particular embodiments, the gear set may be: integral to the valveactuator; external to a housing that contains the solid-state motorcontroller; operable to directly mate with a valve stem of a valve;operable to directly mate with a hollow shaft or a linear motor that canbe directly coupled to a valve or an actuator-driven load; and/oroperable to directly mate with a hollow shaft having a three-positionmotor/handwheel clutching system and solenoid-driven brake.

The valve actuator may further include a valve actuator controller. Thevalve actuator controller may be integral to the valve actuator and/oroperable to send and receive signals. The received signals may includecommand signals and feedback signals, process variable set-point signalsand position signals, and process variable feedback signals and motorposition signals. The valve actuator controller may be capable ofproportional control, proportional plus integral control, proportionalplus derivative control, or proportional plus integral plus derivativecontrol of a process by controlling the actuation of a valve. The valveactuator controller may comprise logic for determining the speed andtorque at which a valve will be actuated. In a particular embodiment,the motor controller is integrated within the valve actuator controller.

In another embodiment, the valve actuator may further include afield-connection block operably coupled to the motor controller. Thefield-connection block may be operably coupled to a power converter,which can be operably coupled to the motor controller. Thefield-connection block may be a universal field-connection block.

In a particular embodiment, a valve actuator includes: a universalfield-connection block; a power converter operable to receive a powersupply; a variable-speed motor; a solid-state motor controller operablyconnected to the power converter and the motor controller configurableto operate the variable-speed motor; and a braking device operablyconnected to the variable-speed motor, the braking device comprised of agear set.

In another embodiment, the valve actuator includes: a housing; a motorcontroller; a variable-speed motor with an output shaft, wherein thevariable-speed motor is configured for control by the motor controller;the motor controller and the variable-speed motor integrated within thehousing; and a gear train outside of the housing and operatively coupledto the output shaft. The valve actuator may further include a powerconverter operatively coupled to the motor controller. The housing canbe a motor housing. The motor housing may be located interior to anactuator housing.

A system for actuating a valve may include: a valve actuator, whereinthe valve actuator comprises: a motor, wherein the motor comprises anoutput shaft; a solid-state motor controller operably connected to themotor and capable of operating the motor at variable speeds and torques;and a gear set coupled to the output shaft of the motor.

A method of operating a valve actuator may include: providing a valveactuator comprising a solid-state motor controller operably connected toa variable-speed motor, wherein a gear set is operably connected to thevariable-speed motor; setting the speed on the solid-state motorcontroller at which the variable-speed motor will be driven by thesolid-state motor controller when the valve actuator is operated; andlocking the variable-speed motor with the gear set against back-drivingloads in the event of a power failure. The method may further comprisesetting the torque on the solid-state motor controller that will begenerated by the variable-speed motor when the valve actuator isoperated.

A method of actuating an electrically driven valve actuator may include:receiving a command signal at a solid-state valve actuator controlleroperably connected to the electrically driven valve actuator including agear set, wherein the electrically driven valve actuator is capable ofvariable speeds; receiving a feedback signal at the solid-state valveactuator controller; determining if there is a difference between thecommand signal and the feedback signal; and minimizing any differencebetween the command signal and the feedback signal by actuating theelectrically driven valve actuator. The command signal may include aprocess variable set-point signal and the feedback signal comprises aprocess variable feedback signal. Minimizing any difference between thecommand signal and the feedback signal by actuating the electricallydriven valve actuator can be accomplished by actuating the electricallydriven valve actuator at a constant speed, by actuating the electricallydriven valve actuator at a constant torque, or by actuating theelectrically driven valve actuator at varying speeds over the length ofa valve stroke.

While disclosed with particularity, the foregoing techniques andembodiments are more fully explained and the invention described by thefollowing claims. It is clear to one of ordinary skill in the art thatnumerous and varied alterations can be made to the foregoing techniquesand embodiments without departing from the spirit and scope of theinvention. Therefore, the invention is only limited by the claims.

What is claimed is:
 1. A valve actuator comprising: a housing; a motorcontroller; a variable speed motor with an output shaft, wherein thevariable speed motor is configured for control by the motor controller;and the motor controller and the variable speed motor integrated withinthe housing; and a gear train outside of the housing and operativelycoupled to the output shaft; wherein at least one of the variable speedmotor, the gear train and the valve is configured to generate feedbacksignal receivable by the motor controller, the feedback signalindicating at least one of torque and speed thereof.
 2. The valveactuator of claim 1, further comprising a power converter operativelycoupled to the motor controller.
 3. The valve actuator of claim 1,wherein the variable speed motor is selected from the group consistingof an AC synchronous reluctance motor with motor position feedback, anAC synchronous reluctance motor without motor position feedback, a DCbrushless motor with motor position feedback, and a DC brushless motorwith motor position feedback.
 4. The valve actuator of claim 1, whereinthe variable speed motor is an AC motor selected from the groupconsisting of: single-phase induction motors, poly-phase inductionmotors, wound-rotor motors, multi-speed motors, constant torque motors,variable torque motors, universal motors, synchronous hysteresis motors,DC-excited synchronous motors, servomotors, brushless servo motors, andlinear motors.
 5. The valve actuator of claim 1, wherein the variablespeed motor is a DC motor selected from the group consisting of:shunt-wound, series-wound, compound-wound, brushless DC motors, linearmotors, brushless linear motors, coreless motors, ring motors, pancakemotors, limited-angle torque motors, permanent magnet stepper motors,variable reluctance motors, switched reluctance motors, and servomotors.
 6. The valve actuator of claim 1, further comprising a valveactuator controller.
 7. The valve actuator of claim 6, wherein the valveactuator controller is integral to the valve actuator.
 8. The valveactuator of claim 6, wherein the motor controller is integrated withinthe valve actuator controller.
 9. The valve actuator of claim 1, furthercomprising a field connection block operably coupled to the motorcontroller.
 10. The valve actuator of claim 1, wherein the motorcontroller is configured to receive a process variable set-point signaland a process variable feedback signal, determine if there is adifference between the process variable set-point signal and the processvariable feedback signal, and minimize any difference between theprocess variable set-point signal and the process variable feedbacksignal by actuating the electrically driven valve actuator
 11. A methodof operating a valve actuator, the method comprising: providing thevalve actuator of claim 1; setting the speed on the motor controller atwhich the variable speed motor will be driven by the motor controllerwhen the valve actuator is operated; and locking the variable speedmotor with the gear set against back driving loads in the event of apower failure.